Power generation systems

ABSTRACT

A power generation system is provided that includes an internal combustion engine configured to provide rotational mechanical energy. A generator is configured to receive the rotational mechanical energy and generate electrical power in response to the rotational mechanical energy. A fluid medium is provided to the internal combustion engine and to the generator for removing thermal energy from the internal combustion engine and from the generator.

CROSS REFERENCE TO RELATED APPLICATION

This patent resulted from a continuation application of U.S. patentapplication Ser. No. 12/719,726, filed Mar. 8, 2010, now issued U.S.Pat. No. 7,969,030 dated Jun. 28, 2011, of which was a continuationapplication of, and claims priority to U.S. patent application Ser. No.10/577,577, filed Sep. 21, 2006, now issued U.S. Pat. No. 7,675,187dated Mar. 9, 2010, which claims priority to PCT InternationalApplication Number PCT/US04/32857, filed Oct. 5, 2004, published inEnglish, and which claims priority to U.S. Provisional PatentApplication No. 60/508,857, filed Oct. 6, 2003, and the teachings of allthe applications are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to power generation systems and methods ofgenerating power.

BACKGROUND ART

The current products offered by the portable power generation industryare deficient in meeting customer needs. For example, current portablegenerator sets are limited to single voltages at a designed outputfrequency, that is, the generator sets operate at fixed revolutions perminute (rpms) which is limiting the usefulness of current portable powergeneration systems. To handle the needs of customers that operate in aglobal environment, portable generator sets are either reconfiguredafter purchase, or multiple portable generator sets are purchased thatoperate with different respective frequencies and voltages. Portablepower generation systems are needed to resolve these issues and morereadily meet the needs of customers.

Moreover, the portable power generation industry continues to strive tomeet customer demands for products that are light in weight, small insize (including footprint dimensions) and fuel efficient. For example, aconventional generator set (gen set) comprises a longitudinal orlength-wise dimension of approximately sixty inches without a heatexchanger and weighs approximately 2,000 pounds.

Furthermore, the portable power generation industry continues to striveto meet the needs of customers that use generators and generator sets asauxiliary power units (APUs). For example, improvements are needed forauxiliary power units used in the trucking business such as the tractortrailer and/or long haul trucking industry. As environmental concernsresult in more stringent noise and air emission regulations, truckoperators are continually being prevented from operating their enginesin more areas, for example, truck stops, loading docks and rest areasdue to emission regulations and no-idle laws. This translates into thetruck operator being prevented from operating modern conveniences suchas an on-board air conditioner, refrigerator, radio and/or television.It also translates into the truck operator not being able to performbusiness tasks that are work-related which require an on-board computer.Portable power generation systems are needed as solutions to resolvethese issues and respond to market and regulatory pressures in thetrucking industry. Additionally, the portable power generation industrycontinues to strive to meet the demands of truck drivers for APUs thatensure that parasitic loads of a truck engine are maintained at aminimum.

Still further, the transportation industry continues to strive toproduce fuel efficient and environmentally-friendly vehicles. Thismotivation as led to alternative power generation designs andtechnologies for the vehicles, such as electric vehicles and hybridelectric vehicles. These vehicular designs have unique powerapplications and demands wherein a power plant provides batterycharging, power for peak load requirements, absorption of braking energyand power for prime loads. Important design considerations andparameters for the power plants are size and weight because suchparameters drive the load and physical size of the vehicle. Anadditional design consideration should be reflected in a customer's needfor systems capable of withstanding exposure of rain, dust or otherexternal environmental conditions. A need exists for power generationsystems designed to meet the unique considerations and parameters ofelectric vehicles and hybrid electric vehicles.

Additionally, conventional motor-generator systems or generator sets areused to transform power and/or isolate power from one source to another.The application typically involves the coupling of an AC motor which iscoupled with an AC or DC radial gap generator to create DC power or adifferent voltage & frequency of AC power. There is a continual need tooptimize the size, weight and cost of conventional motor-generatorsystems. This is especially true for military applications, for examplethe Navy branch and any industry dealing with boating, which requirehigh tolerance parameters and specifications with regard to cooling,weight and space requirements for power generation. Thermodynamicmanagement in these applications have proven difficult and veryexpensive. Accordingly, there is a need to provide a motor-generatorsystem or set that resolves these problems of the conventionalmotor-generator systems.

SUMMARY

In one aspect of the invention, a power generation system is providedthat includes an internal combustion engine configured to providerotational mechanical energy. A generator is configured to receive therotational mechanical energy and generate electrical power in responseto the rotational mechanical energy. A fluid medium is provided to theinternal combustion engine and to the generator for removing thermalenergy from the internal combustion engine and from the generator.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below withreference to the following accompanying drawings.

FIG. 1 is a block diagram of an exemplary power generation systemaccording to embodiments of the invention.

FIG. 2 is a block diagram of an exemplary power generation systemaccording to other embodiments of the invention.

FIG. 3 is a side elevational view of an exemplary power generationsystem according to an embodiment of the invention.

FIG. 4 is the FIG. 3 view emphasizing components of the exemplary powergeneration system.

FIG. 5 is an elevational front view of the FIG. 3 power generationsystem.

FIG. 6 is the FIG. 5 view emphasizing components of the exemplary powergeneration system.

FIG. 7 is a side elevational view of the FIG. 3 power generation systemillustrating a side view opposite the FIG. 3 side view.

FIG. 8 is the FIG. 7 view emphasizing components of the exemplary powergeneration system.

FIG. 9 is a top plan view of the FIG. 3 power generation system.

FIG. 10 is the FIG. 9 view emphasizing components of the exemplary powergeneration system.

FIG. 11 is an elevational back view of the FIG. 3 power generationsystem.

FIG. 12 is a perspective view of an exemplary flywheel according to anembodiment of the invention.

FIG. 13 is a perspective view of an exemplary generator according to anembodiment of the invention.

FIG. 14 is a sectional view of the FIG. 13 generator.

FIG. 15 is a perspective view of an exemplary heat exchanger accordingto an embodiment of the invention.

FIG. 16 is a perspective side view of an exemplary power electronicsdevice according to an embodiment of the invention.

FIG. 17 is a perspective side view of the FIG. 16 power electronicsdevice illustrating a side view opposite the side view of FIG. 16.

FIG. 18 is a perspective view of an exemplary support structureaccording to an embodiment of the invention.

FIG. 19 is a block diagram of the exemplary components monitored by anexemplary package control unit (also referred to as unit control)according to embodiments of the invention.

FIG. 20 is a block diagram of the exemplary components monitored by anexemplary power control (also referred to as power electronics device)according to embodiments of the invention.

FIG. 21 is a block diagram of an exemplary ignition control according toembodiments of the invention.

FIG. 22 is a block diagram of an exemplary Unit Control/Logic Controlaccording to embodiments of the invention.

FIG. 23 is a block diagram of an other exemplary Unit Control/LogicControl according to embodiments of the invention.

FIG. 24 is a block diagram of an exemplary method for generating poweraccording to one of various embodiments of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, an overview of an exemplary embodiment of a powergeneration system 10 according to the invention is illustrated as ablock diagram. An exemplary power generation system 10 includes a systemfor a generator and/or a generator set. In one exemplary embodiment ofthe power generation system 10, a rotational power source 20 has anoutput in the form of rotational mechanical energy provided by an outputshaft 22 which rotates having a rotational speed in revolutions perminute (rpm). The rotational mechanical energy of rotating output shaft22 is transferred to a generator 24 which converts the rotationalmechanical energy of rotating output shaft 22 into electrical energy andthermal energy (i.e., electricity and heat, respectively). Electricaloutput of the generator 24 is in relation to the speed of the outputshaft 22 of the rotational power source 20. Energy loss in the form ofheat is incurred in the process of converting rotational mechanicalenergy into electrical energy. In one exemplary embodiment of system 10,generator 24 is coupled in fluid communication with a heat exchanger 26wherein at least a portion of the thermal energy (i.e., heat) producedin generator 24 is transferred to a fluid medium, for example, airand/or a liquid which is provided to generator 24 via a fluid conduit(shown subsequently), for example, a hose or pipe between the generator24 and heat exchanger. Additionally, portions of heat are transferred tooutside surfaces of generator 24 from which the heat is transferred tothe surrounding air or environment. In some embodiments, the powergeneration system includes a heat exchanger 26. In some embodiments,heat exchanger 26 or cooler is included within an array or network ofheat exchanger units. An exemplary array or network is coupled in heatexchanging relation to fluid using a fluid conduit, for example, a hoseor tube.

Still referring to FIG. 1, the generator 24 is coupled, using interface32, with a power electronics device 28, or power conversion device.Electricity produced by the generator 24 is transferred to the powerelectronics device 28 to be converted into a form desired by theoperator of the power generation system 10. In one embodiment of system10, thermal energy generated by a power electronics device 28 is atleast partially removed by a fluid, for example, by air and/or a liquid.In some embodiments of system 10, thermal energy generated by a powerelectronics device 28 is at least partially removed by a liquid. Thepower electronics device 28 comprises a heat exchanger 30 coupled influid communication with a heat exchanger 30 by a liquid cooling circuit(illustrated more thoroughly subsequently). Heat produced in the processof converting the generated electricity into a form that is selected bythe operator is transferred to the liquid cooling circuit from the powerelectronics device 28 and to a heat exchanger 30. Heat from the heatexchanger 30 is transferred to the environment and/or another medium. Insome embodiments of system 10, the heat exchanger 30 comprises anindependent unit. In other embodiments of system 10, the heat exchanger30 is combined within a network of at least one other heat exchangerunit, for example, a network that includes heat exchanger 26. A powerelectronics device 28 is capable of power conversions or signalconversions from an input source to an output source, for example, fromAC to DC, DC to AC, and AC to AC. The power electronics device 28 iscapable of one or a multiple of the aforementioned conversions. In someembodiments of power generation system 10, an operator is able toconfigure, reconfigure and/or modify the power electronics device 28such that output current, frequency, voltage and/or polarity areselectable.

Still referring to FIG. 1, the power electronics device 28 is coupled tooutput connection(s) 36. Converted electricity having the selectedoutput current, frequency, voltage and/or polarity is transferred to theoutput connection(s) 36. In some embodiments, the output connection 36is an integral component of the power electronics device 28. In otherembodiments, the output connection 36 comprises a stand-alone componentconnected to the power electronics device 28 by an interface 34. Theoutput connection 36 provides an interface between the power generationsystem 10 and an electrical load (not shown).

Still referring to FIG. 1, an exemplary power generation system 10comprises a control unit 38 that monitors the respective components anddevices discussed previously, for example, rotational power source 20,generator 24, power electronics device 28 and output connection 36,respectively. An array 40 of data conduits are coupled between thepackage control unit 38 and the respective devices to communicate inputand output data between the respective devices. The exemplary controlunit 38 has the capability to perform one or more of the followingfunctions: monitor the power generation system 10, diagnose problemswithin the power generation system 10, control components of the powergeneration system 10, annunciate status of components of the powergeneration system 10, and supervise the power generation system 10. Insome embodiments, the package control unit 38 may also function as aninterface for local and/or remote monitoring and control.

It should be understood that various combinations of devices (e.g.,rotational power source 20, generator 24, power electronics device 28and output connection 36, respectively) can be coupled in fluidcommunication to various combinations of heat exchangers. For example, apower generation system 10 can comprise a single heat exchanger standingalone and coupled in fluid communication with a single device 20, 24,28, 36. That is, a single heat exchanger can be coupled to a singledevice 20, 24, 28, 36. Alternatively, one or more heat exchangers can becoupled to a single device. For example, two or more heat exchangers canbe coupled in fluid communication with generator 24, and the combinationof heat exchangers can be in fluid communication with one another, ornot in fluid communication with one another. Alternatively, one or moredevices can be coupled to a single heat exchanger. For example, two ormore devices, for example, rotational power source 20 and generator 24,can be coupled in fluid communication with a single heat exchanger 26,and the combination of devices can be in fluid communication with oneanother, or not in fluid communication with one another. Moreover, anexemplary power generation system 10 can include a single device 20, 24,28, 36 coupled to a single heat exchanger and include another singledevice coupled to a plurality of heat exchangers. Additionally, anexemplary power generation system 10 can include a single device coupledto a single heat exchanger and include another single heat exchangercoupled to a plurality of devices. Furthermore, an exemplary powergeneration system 10 can include any combination of the examplespresented above. For example, an exemplary power generation system 10can include a plurality of devices coupled to a single heat exchanger ora plurality of heat exchangers; and include another single devicecoupled to another single heat exchanger; and include a plurality ofheat exchangers coupled to another single device or coupled to anotherplurality of heat exchangers; and added to this exemplary powergeneration system 10 can include any additional combination of devicescoupled to additional combination of heat exchangers.

Referring to FIG. 2, an overview of another exemplary embodiment of apower generation system 60 is illustrated as a block diagram. Powergeneration system 60 includes a system for a generator and/or agenerator set. In one exemplary embodiment of the power generationsystem 60, a fuel supply 62 provides chemical energy to a rotationalpower source 64 via a fuel conduit 66. In some embodiments, fuel supply62 is cooled by a fluid, for example, a liquid. In these embodiments,fuel supply 62 is coupled, for example, in fluid communication to a heatexchanger 68 to at least partially remove thermal energy from the fuelsupply 62. An exemplary heat exchanger 68 defines an independentcomponent of power generation system 60. In another embodiment, heatexchanger 68 is combined within a network of at least one other heatexchanger units. Rotational power source 64 comprises an output shaft 70and converts chemical energy from fuel supply 62 into rotationalmechanical energy at the output shaft 70. Rotational power source 64 iscoupled in fluid communication with a heat exchanger 72. At least aportion of heat generated in converting chemical energy to rotatingmechanical energy is transferred to a fluid medium, for example, aliquid provided to the rotational power source 64 via a cooling circuit.An exemplary heat exchanger 72 defines an independent component of powergeneration system 60. In other embodiments, heat exchanger 72 iscombined within a network of at least one other heat exchanger unit, forexample, heat exchanger 68.

Still referring to FIG. 2, the rotating output shaft 70 of rotationalpower source 64 is coupled to a gearbox 74 to transfer rotatingmechanical energy from the rotational power source 64 to the gearbox 74.The gearbox 74 comprises an output shaft or drive shaft 78 that iscoupled to a generator 76. The shaft 78 transfers rotational mechanicalenergy of output shaft 70 from rotational power source 64 to the driveshaft 78 which drives generator 76. An exemplary gearbox 74 isconfigured to selectively increase or decrease the rotating speed ofoutput shaft 70 of rotational power source 64 which corresponds toselectively increasing or decreasing the rotating speed of drive shaft78 which corresponds to selectively increasing or decreasing therotating speed of generator 76. Such exemplary selectivity of gearbox 74ensures generator 76 operates at an optimal speed. Thermal energy isgenerated within the gearbox 74 during the conversion of increasing ordecreasing rotational speed of the output shaft 70 to drive shaft 78. Inone exemplary embodiment, drive shaft 78 is coupled in fluidcommunication with a heat exchanger 80 wherein at least a portion ofheat generated in converting the rotating mechanical energy ofrespective shafts 70 and 78 is transferred to a fluid medium, forexample, air and/or a liquid which is provided to the gearbox 74 via aconduit, for example, a hose or pipe (shown subsequently). An exemplaryheat exchanger 80 defines an independent component of power generationsystem 60. In other embodiments, heat exchanger 80 is combined within anarray or network of at least one other heat exchanger unit, for example,with heat exchanger 68 or with heat exchanger 72, or with both. Anexemplary array or network is coupled in fluid communication by anexemplary conduit, for example, a hose or tube.

The generator 76 converts rotating mechanical energy into electricalenergy and thermal energy (i.e., electricity and heat). In one exemplaryembodiment, generator 76 is coupled in fluid communication with a heatexchanger 82 wherein at least a portion of heat generated in the processof converting mechanical energy into electricity is transferred to afluid medium, for example, air and/or a liquid which is provided to thegenerator 76 via a conduit, for example, a hose or pipe (shownsubsequently). An exemplary heat exchanger 82 defines an independentcomponent of power generation system 60. In another embodiment, heatexchanger 82 is combined within an array or network of at least oneother heat exchanger unit, for example, with heat exchanger 68 or withheat exchanger 72, or with both. An exemplary array or network iscoupled in fluid communication by an exemplary conduit, for example, ahose or tube.

Electricity produced by the generator 76 is transferred to a powerelectronics device or power conversion device 84. Electricity producedby the generator 76 is transferred to the power electronics device 84 tobe converted into one or more forms as desired by the operator of thepower generation system 60. In one exemplary embodiment, powerelectronics device 84 is coupled in fluid communication with a heatexchanger 86 wherein at least a portion of heat generated in the processof converting one form of electricity to another form of electricity istransferred to a fluid medium, for example, air and/or a liquid which isprovided to the power electronics device 84 via a conduit, for example,a hose or pipe (shown subsequently). An exemplary heat exchanger 86defines an independent component of power generation system 60. Inanother embodiment, heat exchanger 86 is combined within an array ornetwork of at least one or more heat exchanger units, for example, withheat exchanger 68, 72, 80, and/or 82, singularly or in any combinationthereof. An exemplary array or network is coupled in fluid communicationby an exemplary conduit, for example, a hose or tube. In an exemplaryembodiment, the power electronics device 84 has the capability tointerface with a secondary power source 100. The secondary power source100 is capable of providing a secondary power input to the powerelectronics device 84 via an interface and/or receiving power from thepower electronics device 84 for distribution or storage. Exemplarydevices for exemplary secondary power source 100 include anothergenerator, utility feed, flywheel energy storage device, batteries,capacitors (super) or other energy sources. An exemplary powerelectronics device 84 will manage various combinations of electricalcurrent for example:

Primary input Secondary input Output AC — AC* AC AC AC* AC DC AC* AC DC*AC AC DC* AC DC AC* DC AC* DC AC AC* DC DC AC* DC AC* DC AC DC* DC DCDC* *Capable of one or a multiple of the outputs.

An exemplary power electronics device 84 provides an output that isfrequency selectable, voltage selectable, and polarity selectable. Anexemplary power electronics device 84 provides an output that includesdigital grade power. An exemplary power generation system 60 comprisesan output of the power electronics device 84 that is transferred totransformer 88 via an interface. An exemplary power generation system 60comprises an exemplary transformer 88 coupled to a distribution panel 94via an interface 92 wherein the distribution panel 94 is coupled topower loads to be used by a consumer. In one exemplary embodiment, anexemplary transformer 88 is coupled in fluid communication with a heatexchanger 90 wherein at least a portion of heat generated in thetransformer 88 is transferred to a fluid medium, for example, air and/ora liquid which is provided to the transformer 88 via a conduit, forexample, a hose or pipe (shown subsequently). An exemplary heatexchanger 90 defines an independent component of power generation system60. In another embodiment, heat exchanger 90 is combined within an arrayor network of at least one or more heat exchanger units, for example,with heat exchanger 68, 72, 80, 82 and/or 86, singularly or in anycombination thereof. An exemplary array or network is coupled in fluidcommunication by an exemplary conduit, for example, a hose or tube.

Still referring to FIG. 2, power generation system 60 comprises apackage control unit 96 that monitors the respective components anddevices discussed previously, for example, fuel supply 62, rotationalpower source 64, gearbox 74, generator 76, power electronics device 84,transformer 88 and distribution panel 94, respectively. An array 98 ofdata conduits are coupled from the power electronics device 84 to therespective devices to communicate input and output data between therespective devices and the power electronics device 84. The exemplarypackage control unit 96 has the capability to perform one or more of thefollowing: monitor components of the power generation system 60,diagnose problems with components of the power generation system 60,control components of the power generation system 60, annunciate statusinformation relating to components of the power generation system, andsupervise the power generation system 60. In another exemplaryembodiment, the package control unit 96 may also function as aninterface for local and/or remote monitoring and control.

It should be understood that the plurality of various combinations ofdevices (e.g., fuel supply 62, rotational power source 64, gearbox 74,generator 76, power electronics device 84, transformer 88, respectively)can be coupled in fluid communication to the following plurality ofvarious combinations of heat exchangers for an exemplary powergeneration system 60. For example, an exemplary power generation system60 can comprise a single heat exchanger standing alone and coupled influid communication with a single device. That is, a single heatexchanger can be coupled to a single device. Alternatively, one or moreheat exchangers can be coupled to a single device. For example, two ormore heat exchangers can be coupled in fluid communication withgenerator 76, and the combination of heat exchangers can be in fluidcommunication with one another, or not in fluid communication with oneanother. Alternatively, one or more devices can be coupled to a singleheat exchanger. For example, two or more devices, for example,rotational power source 64 and generator 76, can be coupled in fluidcommunication with a single heat exchanger, and the combination ofdevices can be in fluid communication with one another, or not in fluidcommunication with one another. Moreover, an exemplary power generationsystem 60 can include a single device coupled to a single heat exchangerand include another single device coupled to a plurality of heatexchangers. Additionally, an exemplary power generation system 60 caninclude a single device coupled to a single heat exchanger and includeanother single heat exchanger coupled to a plurality of devices.Furthermore, an exemplary power generation system 60 can include anycombination of the examples presented above. For example, an exemplarypower generation system 60 can include a plurality of devices coupled toa single heat exchanger or a plurality of heat exchangers; and includeanother single device coupled to another single heat exchanger; andinclude a plurality of heat exchangers coupled to another single deviceor coupled to another plurality of heat exchangers; and added to thisexemplary power generation system 60 can include any additionalcombination of devices coupled to additional combination of heatexchangers.

Referring to FIGS. 3-11, an exemplary embodiment of a power generationsystem 200 is illustrated. Components of an exemplary embodiment of apower generation system 200 are illustrated in FIGS. 12-18. It should beunderstood that power generation system 200 can be used for the powergeneration systems discussed above with respect to FIGS. 1 and 2. Itshould also be understood that the specific components of FIGS. 12-18and schematics presented in FIGS. 20-24 can be used for the powergeneration systems discussed above with respect to FIGS. 1-2 and powergeneration system 200. It should be understood that FIG. 19 illustratesanother exemplary power generation system 840 that can be used for thepower generation systems discussed above with respect to FIGS. 1 and 2,and include the specific components of FIGS. 12-18 and include theschematics presented in FIGS. 20-24.

Power generation system 200 comprises a rotational power source 208, forexample, an internal combustion engine, such as a gasoline engine or adiesel engine. In one exemplary embodiment, the rotational power sourcecomprises a diesel engine 208. An exemplary diesel engine 208 isdesigned with an optimal gear train (not shown) within the engine byhaving a front gear train of two high-contact-ratio gears mounted to theengine block and has the added benefit of low noise characteristics. Anexemplary diesel engine 208 includes a fuel system that has mechanicallygoverned unit pumps (not shown) mounted inside the engine block whicheliminates external high-pressure lines, minimizes leak paths andreduces noise levels. This fuel system contributes to cost effectivenessand clean design. One example of a diesel engine that could be employedfor the diesel engine 208 is an industrial engine that is commerciallyavailable from John Deere as model 4024T 66 hp Diesel Engine(www.deere.com).

The diesel engine 208 has an output providing rotational mechanicalenergy in the form of an output shaft (not shown) which is rotatable andis coupled to a rotational coupling device which couples engine 208 to agenerator (only generator housing 360 shown in FIG. 3). An exemplaryrotational coupling device comprises a flywheel which provides therotational mechanical energy of rotating output shaft to the generatorfor conversion into electrical and thermal energy (i.e., electricity andheat, respectively). An example of a flywheel that could be employed forthe flywheel 600 illustrated in FIG. 13 (only flywheel housing 340 isshown in FIG. 3) is commercially available from ARCUSAFLEX® FlywheelCouplings as model Ringfeder Arcusaflex Coupling (www.ringfeder.com).

Referring to FIG. 12, an exemplary flywheel 600 comprises a couplingring 602 which forms a cylindrical opening 604 to receive the shaft ofthe generator which provides the coupling of the flywheel 600 to thegenerator. In one embodiment, an exemplary flywheel 600 comprises arubber disk component 606 which permits the shaft of the generator to beprovided at angular, axial and parallel misalignments and also dampensvibrations.

Referring to FIGS. 13-14, an exemplary generator 640 is illustrated(only generator housing 360 is shown in FIG. 3) and comprises a flangeportion 642 for securing generator 640 to a structure or component ofpower generation system 200 (FIG. 3). An exemplary generator 640comprises a housing 644 integral with flange portion 642 for protectingand enclosing the internal structure and components 648 of generator640. Referring to FIG. 3, an exemplary generator housing 360 seals andprotects generator 640 from the environment and can withstand water andsand exposure. An example of a generator that could be employed for thegenerator 640 is commercially available by TM4 Energy as model TM4 40 kwgenerator.

Referring to FIG. 3, an exemplary power electronics device 300 isillustrated positioned elevationally above generator housing 360. Itshould be understood that power electronics device 300 could bepositioned in any location relative the other components of powergeneration system 200. Power electronics device 300 comprises an array302 of output connections 308. Output connections 308 compriseelectrical ports to be used by the consumer for connection to loadspermitting the consumer to use the electrical energy produced by thegenerator. An exemplary power electronics device 300 is a powerconversion device that converts the output of the generator (AC or DC)into a useable voltage (AC or DC) and frequency (50 Hz, 60 Hz, etc.).The exemplary power electronics device 300 is sealed from theenvironment and can withstand water immersion and survive up to 50 grepetitive shock (vibration) loads. Components of the power electronicsdevice 300 are mounted on a hollow plate wherein fluid (coolant) from anheat exchanger passes through the hollow portion of the plate to removeheat from the power electronics device 300 generated in the powerconversion process (loss due to inefficiencies). In one embodiment, thepower electronics device 300 is integrated into the generator housing360, or be an independent component that is mounted on the frame(discussed more thoroughly subsequently). An exemplary power electronicsdevice 300 comprises a size that ranges from five times to ten timesless than the size of a conventional power electronics device.

Referring to FIGS. 16-17, an exemplary power electronics device 700 isillustrated in more detail. Power electronics device 700 comprisescooling ports 706 and 708 for coupling to an exemplary heat exchangerfor fluid transport. Power electronics device 700 further compriseselectrical connections/ports 716 and communication ports 710 and 712. Anexemplary power electronics device 700 comprises a resistancetemperature device (RTD) 714 and center-of-gravity mounts 718 to impedeshock and vibrations to the power electronics device 700. Housingportions 702 and 704 protect and enclose structure within powerelectronics device 700. An example of a power electronics device thatcould be employed for the power electronics device 700 is commerciallyavailable from Rockwell Automation as model LiquiFlo ProPulse PowerModule.

Referring to FIGS. 7-8, an exemplary power generation system 200includes a package control unit 500 illustrated as being positionedadjacent engine 208 and includes a display window 502. It should beunderstood that package control unit 500 could be positioned in anylocation relative the other components of power generation system 200.An exemplary package control unit collects, shares and transmitspertinent information between specific system components of powergeneration system 200 to effectively manage and optimize the collectivecooperation between the components of the power generation system 200.For example, with respect to the engine, an exemplary package controlunit 500 will monitor engine output (hp, torque, speed), batteryvoltage, engine temperature, exhaust temperature and engine oiltemperature. With respect to the generator, an exemplary package controlunit 500 will monitor the generator output and the temperature of thefluid (coolant) within the generator from the heat exchanger. Withrespect to the power electronics device, an exemplary package controlunit 500 will monitor the temperature of the fluid (coolant) within thepower electronics device, and monitor the electrical input to and outputfrom the power electronics device.

With respect to the heat exchanger, an exemplary package control unit500 will monitor two components (discussed more thoroughly below) of theheat exchanger, a hot circuit and a cold circuit. The hot circuit hastwo components which is represented here as hot circuit #1 and hotcircuit #2, and the cold circuit has one component. The exemplarypackage control unit 500 will monitor inlet and outlet temperatures ofthe cold circuit and monitor the inlet and outlet temperatures of thehot circuit #1 and hot circuit #2, respectively. An example of a packagecontrol unit that could be employed for the package control unit 500 iscommercially available from Woodward as model easY™gen generator setcontrol model “1500”.

Referring to FIG. 3, an exemplary heat exchanger 400 is illustratedpositioned at an end of the power generation system 200 opposite engine208. It should be understood that the heat exchanger could be positionedin any location relative the other components of power generation system200. An example of a heat exchanger comprises a plate and frame designand is commercially available by Sondex as model Jernet 9(www.sondexuk.com/gasketed). This plate and frame design of theexemplary heat exchanger comprises two fluids that pass in oppositedirections up and down alternative channels formed in exemplary pressedplate packs 409 and 413 discussed more thoroughly below.

Referring to FIG. 15, in one exemplary embodiment, the heat exchanger400 comprises frame side structures 405 and 407 secured on oppositesides of the respective plate packs 409 and 413 by, for example,clamping bolts 423. Exemplary frame side structures 405 and 407 comprisemetal and exemplary plate packs 409 and 413 comprise metal. Plate packs409 and 413 are divided by a center frame structure 411 which comprises,for example, a metal plate. Each frame side structure defines openingswhich function as inlets and outlets, for example, openings 410, 414,417, 419 defined by frame side 407.

In some embodiments, the plate and frame design of the exemplary heatexchanger comprises the two hot circuits and the single cold circuit. Insome embodiments, hot circuit #1 is represented as plate pack 413 and isdedicated for the power electronics and generator. In some embodiments,hot circuit #2 is represented as plate pack 409 and is dedicated for theengine cooling circuit. Hot circuit #1 and hot circuit #2 (plate packs409 and 413) are separated by the center frame structure or plate 411.The cold circuit passes first through hot circuit #1 (plate pack 413),and then through hot circuit #2 (plate pack 409) before exiting the heatexchanger 400. That is, each hot circuit #1 and hot circuit #2 (platepacks 409 and 413) also comprises a cold fluid wherein the two fluids,one hot and one cold, pass in opposite directions, up and down inalternative channels formed in the respective plate packs 409 and 413.It should be understood that other exemplary heat exchangers could beused and include a water to air heat exchanger, for example, a radiatorand/or cooling tower.

Referring to FIGS. 3-4, an exemplary conduit system for transferring afluid medium between the heat exchanger 400 and respective components ofpower generation system 200. The conduit system includes a plurality ofdiscrete conduits which can comprise, for example, flexible materialssuch as rubber hoses or inflexible materials such as metal pipes, or anycombination of the various materials. Conduit 216 extends from anopening 404 in heat exchanger 400 to an opening (not referenced) inengine 208 and provides a cooled or cold fluid medium to engine 208 fromheat exchanger 400. The fluid medium enters engine 208 wherein heatenergy from engine 208 is transferred to the fluid medium, and then thefluid medium exits engine 208 from an opening (not referenced) of engine208 to enter conduit 214 wherein the warmed fluid medium returns toenter the heat exchanger through opening 406 to be cooled andre-circulated through conduit 216 and engine 208. It should beunderstood that the path just described for the fluid medium could bereversed through the respective conduits 214 and 216, and engine 208 andheat exchanger 400.

Referring to FIGS. 7-8, an exemplary conduit system for transferring afluid medium between the heat exchanger 400 and respective components ofpower generation system 200 is shown. The plurality of discrete conduitscomprise, for example, flexible materials such as rubber hoses orinflexible materials such as metal pipes, or any combination of thevarious materials. A first conduit 228 extends from an opening 414 inheat exchanger 400 to a first nipple 226 of a pump 220, for example anauxiliary pump, and a second conduit 228 extends from a second nipple222 of auxiliary pump 220 to power electronic device 300. An exemplaryauxiliary pump 220 provides pumping power to transfer a cooled or coldfluid medium to power electronics device 300 from heat exchanger 400.The fluid medium enters power electronics device 300 wherein heat energyfrom power electronics device 300 is transferred to the fluid medium,and then the fluid medium exits power electronics device 300 and entersconduit 304. Conduit 304 extends from power electronics device 300 tothe generator (represented as generator housing 360) and receives thewarmed fluid medium from the power electronics device 300 wherein thewarmed fluid medium is further warmed by receiving heat energy from thegenerator. Conduit 234 extends from the generator to opening 410 of heatexchanger 400 and provides the path for the fluid medium to return tothe heat exchanger 400 from the generator. The fluid medium isre-circulated through the heat exchanger to be cooled and re-circulatedthrough the respective conduits 228, 304 and 234, and the respectivecomponents.

It should be understood that conduits 416 and 418 from respectiveopenings 417 and 419 of heat exchanger 400 are provided to receive afluid medium furnished by a consumer. For example, if power generationsystem 200 is to be provided on a vessel such as a boat, the fluidmedium provided to conduits 416 and 418 can include seawater from theocean. Other exemplary fluid medium include water or air. Either conduit416 and 418 will be an inlet for the fluid medium with the other conduitcomprising an outlet for the fluid medium to be dumped, for example,back into the ocean.

It should be understood that the path just described for the fluidmedium could be reversed through the respective conduits and therespective components. It should be understood that pump 220 can bepositioned in any location relative the respective components of powergeneration system 200, for example, below power electronics device 300and adjacent generator housing 360. It should be understood that pump220 can comprise an electric pump or a mechanical pump. It should beunderstood that pump 220 can be an independent pump driven under its ownpower or driven from engine 208.

Referring to FIG. 4, power generation system 200 has a length 203ranging from about 45 to about 49 inches and defined from one end ofengine 208 to an opposite end of heat exchanger 400. Power generationsystem 200 has a length 201 ranging from about 36 to about 40 incheswithout the heat exchanger 400, and defined from the one end of engine208 to an opposite side of the power electronics device 300. Referringto FIG. 5, power generation system 200 has a height 205 ranging fromabout 28 to about 32 inches and defined from a bottom of engine 208 to atop of engine 208 opposite the bottom. Still referring to FIG. 5, powergeneration system 200 has a width 207 ranging from about 18 to about 22inches and defined from the one side of engine 208 to an opposite sideof engine 208. Power generation system 200 comprises a weight rangingfrom about 800 to about 900 pounds, for example, 850 pounds. Otherdimensions or weights are possible.

Referring to FIG. 18, an exemplary support structure 800 for powergeneration system 200 is illustrated and comprises a frame 801 of anymaterial that is adequately sturdy to support engine 208 and systemcomponents, for example, a metal such as steel. In one exemplaryembodiment, u-shaped base portions 802 extend longitudinally andgenerally in parallel relation wherein spacers 806 are used to maintainthe spaced relation of the u-shaped base portions 802 by extendingbetween and secured to the respective u-shaped base portions 802. Itshould be understood that while only two base portions 802 and twospacers 806 are shown, any number of base portions 802 and spacers 806can be provided for support structure 800. In one exemplary embodiment,base portions 802 comprise the portion of frame 801 to which theadditional structure pieces or sections of frame 801 are secured.Moreover, the exemplary base portions 802 comprise the portion of frame801 which rests and contacts a surface (not shown) to support anexemplary power generation system.

Still referring to FIG. 18, an exemplary frame 801 comprises brackets808 that are secured to and extend upwardly from base portions 802 atone end of an exemplary support structure 800. In one exemplaryembodiment, brackets 808 are secured to base portions 802 by bushings805 that comprise, for example, rubber to dampen vibrations of the powergeneration system 200. Brackets 808 are secured to engine 208, eitherdirectly or with additional bushings (not shown) between brackets 808and engine 208. A pair of cross rails 826 extend between and are securedto respective base portions 802. In one embodiment, cross rails 826support posts 832 which extend upwardly from cross rails 826. Exemplaryposts 832 comprise at least two in number, for example, four and are inspace relation defining a square or rectangle. Exemplary posts 832 areused to support any combination of plurality of components for powergeneration system 200, for example, a power electronics device 834, ageneration housing 836, and other components not shown secured to posts832 such as a package control unit and auxiliary pump. Another pair ofcross rails 828 are located adjacent posts 832 and extend between andare secured to respective base portions 802 to support heat exchanger838. A pair of pillars 816 extend vertically from one base portion 802adjacent two brackets 808 and include a crossbar 817 extending therebetween, and in one exemplary embodiment, pillars 816 and cross bar 817support an auxiliary pump 822 and package control unit 820.

It should be understood that additional structure and beams can beprovided on frame 801 to support additional components, for example, thegenerator. It should be understood that vibration isolators can beprovided between any of the components of the exemplary power generationsystem and frame 801. Conventional generator sets use frames and/orframe rails strong enough to withstand torsional flexing between theengine and generator. However, the exemplary power generation systemsdisclosed herein can be comprised of materials other than steel as aresult of the engine being coupled directly to the generator. That is,with the engine directly coupled to the generator, torsional flexing isreduced and the design allows for off-board components to be betterisolated from vibrations of the engine. Accordingly, in exemplaryembodiments, frame 801 does not have to be designed to overcome thesubstantial torsional flexing of the conventional frames, and therefore,can be designed with materials to provide a frame that is compact andlightweight.

Referring to FIG. 19, an overview 900 of the major components beingmonitored by the Package Control Unit (identified as Unit Control 960 inFIG. 19) according to the invention is illustrated as a block diagram.The Package Control Unit 960 monitors the engine (referenced as primemover 906), generator 908, an ignition control 942 for the engine (primemover 906), heat exchanger 902, the power electronics device (identifiedas power control 920) and customer connections, for example, a 3-phasebreaker 912 to a consumer system 914. These components are coupled byelectrical and/or communication lines 910 and a conduit system 904 ofwater cooling lines.

Referring to FIG. 20, in some embodiments of the power control (powerelectronics device) 920, an exemplary system interface 924 is coupled tologic control 922 that allows the consumer/user to input user settings934. The interface 924 also provides output signals 936. Exemplaryoutput signals 936 can be in text or graphical format on the systeminterface 924, and can be exported as an electronic signal for remoteviewing. The system interface 924 communicates with the logic control922 wherein the logic control 922 receives the user settings 934 fromthe system interface 924 and monitors/regulates Water Cooling andInternal Temperature Sensing 926, DC Regulation 930 and DC-AC Conversion928. In one embodiment, DC Regulation 930 is coupled with DC input oroutput to remote storage system 938. In one embodiment, DC Regulation930 is coupled with AC to DC conversion 932 for exemplary conversionoutputs 940 of 50-690 VAC, poly-phase (for example, 3-18 phases) and50-900 Hertz (Hz). In one embodiment, DC Regulation 930 is coupled withDC to AC conversion 928 for exemplary conversion outputs of 120-690 VAC,1 or 3 phase and 50-1,000 Hertz. Based on User Settings 934 conditions,the Logic Control 922 will manage the power generation system andcommunicate with the System Interface 924 to provide Output Signals 936.

Exemplary User Settings 934 comprise: Frequency Output which sets theoutput frequency of the generator set; Voltage Output which sets theoutput voltage of the generator set; Maximum Power Output which sets themaximum power of the generator set and can not exceed a rated maximumoutput of the engine/generator; Maximum Current Output which sets themaximum current output of the generator set; and Maximum WaterTemperature which sets the maximum water temperature of water (or of anyexemplary fluid medium) exiting an exemplary heat exchanger to thegenerator, power electronics device, and engine.

Exemplary Output Signals 936 comprise: Overtemp Warning which warns ofan over-temperature condition for coolants, fluids, intake air andexhaust of the power generation system; Overtemp Shutdown wherein ashutdown signal is provided due to an over-temperature condition forcoolants, fluids, intake air and exhaust of the power generation system;Overpower Warning which is a warning of an overpower condition for theengine, generator, and/or generator set; Overcurrent Warning which is awarning of an over-current condition for the generator, and/or generatorset; Voltage Output which indicates voltage output for the generator,and/or generator set; Current Output which indicates current output forthe generator, and/or generator set; Frequency Output which indicatesfrequency output for the generator, and/or generator set; DC Bus Voltswhich indicates voltage of a DC Bus; Input Volts which indicates inputvolts to power electronics and/or from secondary power supply; InputFreq which indicates input frequency to power electronics and/or fromsecondary power supply; and Internal Shutdown (Failure) which provides asignal to indicate internal shutdown due to failure of a componentinternal to the generator set.

Referring to FIG. 21, an overview 961 of an exemplary ignition control942 according to embodiments of the invention is illustrated. Theignition control 942 monitors, manages and controls logic blocks thatinfluence ignition of the engine 947. Control logic blocks thatinfluence the ignition of the engine 947 include Air Control 952, FuelControl 950, Ignition Control 942, and Water Cooling Temperature Sensing946. Based on User Settings 954 (via the System Interface 948), theLogic Control 944 will monitor, manage and control logic blocks thatinfluence ignition of the engine 947.

An exemplary Logic Control 944 receives the User Settings 954 from theSystem Interface 948. Via the user settings 954, the Logic Control 944will monitor all parameters for specified maximum or minimum limits. TheLogic Control 944 will then manage one, any combination or all of theblocks that influence the ignition of the engine 947 to prevent theoverall power generation system from exceeding the specified maximum orminimum limits. Based on User Settings 954, the Logic Control 944 willalso communicate with the System Interface 948 to provide Output Signals956.

Still referring to FIG. 21, exemplary User Settings 954 comprise:Operating Mode which can be user specified or automatically determinedwherein Generator Set (engine) can be configured to operate for maximumtorque, maximum power, minimum fuel (fuel efficiency), and/or minimumemissions (low emissions) mode; Desired Speed which specifies thedesired speed of the generator set and/or components of the powergeneration system; Temperature Warning Level which sets the warninglevel for various temperatures of coolants, fluids, intake air and/orexhaust of the power generation system; Temperature Shutdown Level whichsets the shutdown level for the power generation system or componentsthereof based on various temperatures of coolants, fluids, intake airand exhaust of the power generation system; and Run/Start Contact whichspecifies time to crank engine for starting the power generation system.

Still referring to FIG. 21, exemplary output signals 956 comprise:Overtemp Warning which warns of an overtemperature condition forcoolants, fluids, intake air and exhaust of the power generation system;Overtemp Shutdown which provides shutdown signal due to anovertemperature condition for coolants, fluids, intake air and exhaustof the power generation system; Overpower Warning which warns of anoverpower condition for the engine, generator, and/or generator set;Speed (RPM) which indicates speed of prime mover (engine) and generatorin RPM; Delta RPM which indicates differential in desired and actualspeed of prime mover and generator in RPM. (Differential is used whencomparing engine speed and electrical load (demand) at the outputconnections); Actual Engine Mode which indicates actual Mode of engine;Fuel Control Status which indicates actual Mode of Fuel Control 950; AirControl Status which indicates the actual Mode of the Air Control 952;Ignition Control Status which indicates the actual Mode of the IgnitionControl 942; Internal Shutdown (Failure) which provides signal toindicate internal shutdown due to failure of a component which isinternal to the generator set.

Referring to FIG. 22, an exemplary Unit Control/Logic Control 901interacts with the Ignition Control, Heat Exchanger, Generator, PowerControl and Electrical Breaker. The Logic Control 962 is managed basedon inputs from the Operator/User Interface 974. The Operator/UserInterface 974 can be onboard or remote via communication connection. TheLogic Control 962 will monitor and manage the following: Water CoolingTemperature Sensing 964 which senses inlet and outlet temperatures ofcooling fluid medium (e.g., water) and coolant circuits; Interface toIgnition Control 966 which monitors and manages the Ignition Controlunit; Interface to Power Control 968 which monitors and managesparameters associated with the Power Control unit; Current and VoltageInterface 970 which monitors the current and voltage of the generatoroutput; and Breaker Interface 972 which determines if circuit breaker isopen or closed. If a powered breaker is used, the Logic Control 962 maybe used to control the opening and closing of the breaker.

Referring to FIG. 23, another exemplary Unit Control/Logic Control 903configuration is illustrated. An exemplary Unit Control/Logic Controlcomprises a high level interaction between various system controlcomponents. Control components include: Unit Master Controller 992,Engine Control 976, Power Electronics Control 982, and Unit Control BIOS977. For example, an exemplary Unit Control BIOS 977 interacts with UnitMaster Control 992, Engine Control 976, and Power Electronics Control982. The Unit Control Bios 977 contains: Communications Port 939 for thePower Unit; Communications Port 941 for the Ignition Unit; monitoringfor Generator Voltage 943; monitoring for Generator Output Current 945(the parameter values provided in this FIG. for any element/componentare only exemplary, with the ranges of values provided throughout thisdocument being applicable); monitoring for Output Voltage 991;monitoring for Output Current 985; monitoring of the Breaker Control983; monitoring of Temperature Sensing components 981; and monitoringfor optional Analog I/O 979.

Still referring to FIG. 23, in exemplary embodiments, GeneratorFrequency 937 is calculated from Generator Voltage 943. Generator Power933 is calculated from Generator Voltage 943 and Generator Current 945.Output Frequency 987 is calculated from Output Voltage 991. Output Power989 is calculated from Output Voltage 991 and Output Current 985.Moreover, in an exemplary embodiment, the Engine Control 976 interactswith Unit Control BIOS 977, Power Electronics Control 982, and UnitMaster Control 992. The Engine Control 976 contains Start/Stop 978 andSpeed Control 980 blocks. Start/Stop 978 interacts with Unit ControlBIOS 977 and Speed Control 980 blocks. Speed Control 980 interacts withUnit Control BIOS 977, Power Electronics Control 984 and FrequencyControl 986. An exemplary Power Electronics Control 984 interacts withUnit Control BIOS 977, Engine Control 976, and Unit Master Control 992.Power Electronics Control 984 contains Voltage Control 990, VAR Control988, Frequency Control 986, and Power Control 984. An exemplary VoltageControl 990 block interacts with Unit Control BIOS 977, an exemplary VARControl 988 interacts with Unit Control BIOS 977, an exemplary FrequencyControl 986 interacts with Unit Control BIOS 977 and Engine Control 976,and an exemplary Power Control 984 interacts with Unit Control BIOS 977and Engine Control 976.

Referring to FIG. 24, an exemplarily method for generating power 651 isdescribed according to one a various embodiments of the invention.

Still referring to FIG. 24, a first method step 653 includes providing agenerator system comprising a generator having a power output connector.

Still referring to FIG. 24, another exemplary method step 655 includescoupling the power output connector to a first power application, thefirst power application comprising a first power demand.

Still referring to FIG. 24, another exemplary method step 657 includesactivating the generator to provide a first power component to meet thefirst power demand.

Still referring to FIG. 24, another exemplary method step 659 includesmonitoring the first power demand of the first power application.

Still referring to FIG. 24, another exemplary method step 661 includesreceiving an indication that the first power demand has changed to asecond power demand different from the first power demand.

Still referring to FIG. 24, another exemplary method step 663 includesnotifying the generator system of the indication.

Still referring to FIG. 24, another exemplary method step 665 includesafter the notifying, performing one of the following tasks: maintainingthe first power component to meet the second power demand, or modifyingthe first power component to a second power component to meet the secondpower demand, the second power component being different from the firstpower component.

Still referring to FIG. 24, another exemplary method step 667 includeswherein the first and second power components comprise different powerdensity outputs.

In an exemplary embodiment, Unit Master Control 992 interacts withEngine Control 976, Power Electronics Control 982 and Unit Control BIOS977. The Unit Master Control 992 contains Mode Control 995, BreakerControl 994, Load Control 996, and Synchronize Control 997 blocks. ModeControl 995 interacts with Breaker Control 994, Load Control 996, andSynchronize Control 997 within the Unit Maser Control 992. Mode Control995 also interacts with Engine Control 976 and Power Electronics Control982. Breaker Control 994 interacts with Unit Master Control 992, ModeControl 995, and Unit Control BIOS 977. Load Control 996 interacts withUnit Master Control 992, Mode Control 995, Engine Control 976, and PowerElectronics Control 982. Synchronize Control 997 interacts with UnitMaster Control 992, Mode Control 995, Engine Control 976, and PowerElectronics Control 982.

Exemplary embodiments described herein provide advantages and benefitsnot recognized by the conventional power generation systems. Forexample, embodiments of power generation systems described through outthis application (for example, as described in FIGS. 1 and 2, and forpower generation system 200) comprise exemplary generator sets with theability to provide multiple load capability. These exemplary generationsets are capable of managing a primary electrical load as well as asecondary electrical load. In contrast, conventional generator sets arecapable of having only one output for one load which is distributed at aswitchgear or a switchboard. Additionally, the exemplary generation setsaccording to the invention of this disclosure are capable of managingmultiple loads, each having a different voltage, wherein again, theconventional generator sets are capable of having only one output forone load.

Moreover, the exemplary power generation systems/generation setsdisclosed herein comprise global power generation packages that can beconfigured for selectable voltage and/or selectable frequency.Additionally, due to the size (e.g., footprint and weight) of theexemplary power generation systems/generation sets disclosed herein,advantageous mounting configurations are possible. For example, becauseof the smaller footprint and/or size of the generation sets providedherein, the generator can be directly mounted to the engine (primemover) and/or flywheel housing. By being able to mount the generatordirectly to the engine, unique and beneficial mounting configurationsare possible that are not possible with conventional generation sets.Furthermore, the support structure 800 for exemplary power generationsystems disclosed herein, for example, frame 801 illustrated in FIG. 18is lighter in weight compared to frame rails of conventional generationsets, and allows for sensitive components to be isolated from enginevibration.

Furthermore, since the exemplary power generation systems disclosedherein comprise liquid cooled components, for example, the engine (primemover), generator and power electronics, and in combination with thevariable speed operation possible with the system disclosed herein, thecombination allows for a quieter operating power generation system.Additionally, the liquid cooled components of exemplary power generationsystems disclosed herein removes heat from the respective components tothe air in a more optimum mode by, for example, a radiator, coolingtower, keel cooler, etc. Still further, the liquid cooled componentsallow for an enclosure of the power generation systems, or variouscomponents thereof, to be more tightly sealed which reduces sound wavesproduced from the operation of the power generation systems to exitoutside the environment of an exemplary enclosure. Additionally, tightlysealed power electronic devices and generators are less prone to ingressby environmental contaminants such as snow, dirt, sand, bugs and otherdebris. This increases the reliability of the exemplary power generationsystems disclosed herein compared to conventional systems, which isimportant if not imperative for some applications, such as militaryoperations. In fact, the exemplary power generation systems disclosedherein have a N+2 reliability built in, and as a result, is acomparatively higher reliable system.

Furthermore, the variable speed capability of the exemplary powergeneration systems in combination with the liquid cooled componentsallows the power generation systems to operate at higher RPMs thanconventional power generation systems. Higher RPMs produce shorter soundwaves emanating from the exemplary power generation systems, andtherefore, less sound attenuation material is needed to sound proof thepower generation system. Since less sound-proof material is used, theexemplary power generation system will be lighter in weight thanconventional power generation systems. Alternatively, if the same amountof sound-proof material routinely used for conventional power generationsystems is used for the power generation systems disclosed herein, thenthe power generation system disclosed herein will be quieter.

Moreover, the liquid cooled components of the exemplary power generationsystems can contribute to increased fuel utilization. For example,conventional combined heat and power (CHP) applications consist of agenerator set producing electricity with a heat recovery equipment onthe exhaust system. This conventional CHP has the heat from the engine(for example, transmitted to an engine jacket water system) and exhaustsystem transferred to the environment, for example, a building forheating and cooling applications. Moreover, heat rejected from airpassing through the generator is vented to the atmosphere as lostenergy. However, the exemplary power generation systems disclosed hereincan capture the heat energy rejected from the components that arecoupled to heat exchanger(s) in addition to the heat energy capturedfrom the engine water and exhaust system. Additionally, the exemplarypower generation systems disclosed herein allow for more efficientcooling of the environment, for example, the engine room of a vessel orship because the fluid medium which has captured the thermal energy fromthe respective components can be transmitted to remotely mounted coolingdevices such as radiators, cooling towers, etc. The remotely mounting ofcooling devices reduces the need for sizable air handling equipment inthe exemplary engine room of the vessel or ship.

Another advantage/benefit of the exemplary power generation systemsdisclosed herein is the addition of a secondary input allows for zero(0) cycle power outage. For example, the exemplary power generationsystems can use batteries as a secondary input connected to a buildingdistribution system. If the power supply from a municipality isinterrupted or fails, the secondary input will provide power until thegenerator set of the power generation system can be operational. Incontrast, conventional power generation systems need to ramped up toapproximately 1,800 RPMs before closing a coupled breaker system toprovide the power energy to the load (for example, the buildingdistribution system). The exemplary power generation systems disclosedherein will begin producing and providing power energy as soon as thegenerator is turning without any noticeable interruption of power to theconsumer/customer.

Regarding exemplary control schemes for some exemplary embodiments ofthe power generation systems disclosed herein, the system is designed toprovide the engine RPM and generator output to follow the electricalload. Alternatively, for some exemplary embodiments of the powergeneration systems disclosed herein, the systems can have the capabilityto manage or have the operator (consumer/customer) select betweentorque, horsepower and fuel consumption. These configurations forexemplary systems will allow the operator (consumer/customer) tooptimize capabilities of the exemplary systems with respect to differentapplications requiring different power demands.

1. A power generation system comprising: a generator; a powerelectronics device coupled to the generator and comprising first andsecond power application connectors, the first power applicationconnector configured to be coupled to a first power application, thefirst power application is connected to a first power demand, and thesecond power application connector configured to be coupled to a secondpower application, the second power application is connected to a secondpower demand, the second power demand being different from the firstpower demand; the first power application configured to meet the firstpower demand or the second power demand which is connected to the secondpower application; and the second power demand configured to either useor provide power which is different from the first power demand.
 2. Thesystem in claim 1 wherein the second power application is configured touse or provide power to the first power application to meet the firstpower demand based upon an indication of a change in the system.
 3. Thesystem in claim 1 wherein the second power application is configured toselectively contribute in proportion to the first power application tomeet the first power demand.
 4. The system in claim 1 whereinproportions of respective power application contributions are capable ofbeing modified by an external indication to the power generating system,the external indication defining a domain within which the system isselectively configured to operate.
 5. The system in claim 4 wherein theexternal indication is configured to selectively modify the domain toestablish relationships between power applications, power applicationpriorities, power application durability and power generating systemsustainable designed capability.
 6. The system in claim 4 wherein thedomain translates the external indication into unique indications foreach power application in the generating system which provides thecapability to modify the proportion of power application contribution.7. The system in claim 4 wherein the domain comprises logic forestablishing priorities between respective power applications to enablethe power generation system to optimize respective proportions of powerapplications to meet the connected power demands.
 8. The system in claim1 further comprising an interface configured to provide record by timeperiod of: power demand, utilization of design capacity, estimates ofconsumption, estimates of consumption or production by power applicationconnection, and of the cumulative power generation system.
 9. The systemof claim 1 further comprising: a logic control configured to modeldesigned capabilities of respective power applications; and a modecontrol configured to combine the design capabilities to create a designcapability of the power generating system which is different from thedesign capabilities of the respective power applications.
 10. The systemin claim 9 wherein the logic control models: maximum sustainableavailable power to a connected power demand; and maximum intermittentand instantaneous available power.
 11. The system of claim 9 wherein thelogic control is configured to assess the durability of respective powerapplications within the model and indicates the assessment to the powergeneration system.
 12. The system of claim 10 wherein the logic controlis configured to change proportions of contributions of the respectivepower applications to change power available to the respective powerdemands to another maximum sustainable available power.
 13. the systemof claim 9 wherein the mode control is configured to: receive anindication from at least one of the power applications; and in responseto the indication, modify activation and proportion contributions to therespective power applications.
 14. The system of claim 1 furthercomprising: a thermal system connected to components of the powergeneration system; a thermal system sensor in sensing relation with thethermal system; and a thermal component sensor in sensing relation withat least one component of the system.
 15. The system of claim 14 whereinthe thermal system sensor is configured to indicate a temperature of thethermal system that is representative of the maximum sustainable designcapability of the power generation system.
 16. The system of claim 15further comprising, if the temperature is exceeded, a capability toestablish a new maximum sustainable design capability for the powergeneration system.
 17. The system of claim 15 further comprising, if thetemperature is exceeded, a capability to modify proportions of powerapplication contributions to meet the respective power demands.
 18. Thesystem of claim 15 wherein the thermal component sensor is configured toindicate a temperature of the at least one component that isrepresentative of the maximum sustainable design capability of the atleast one component.
 19. The system of claim 18 further comprising thecapability to establish a different maximum sustainable designcapability for the power generation system in response to a temperaturedifferential between the thermal system and the at least one componentthat exceeds a threshold temperature differential representative of themaximum sustainable design capability of the power generation system.20. The system of claim 18 further comprising, in response to thedifferent maximum sustainable design capability, the capability tomodify proportions of power application contributions to meet therespective power demands.